Articulable-arm-mountable pulverisation apparatus and method of use thereof

This application is a U.S. National Stage Application under 35 U.S.C. § 371 of International Patent Application No. PCT/GB2021/053225 filed Dec. 9, 2021, which claims the benefit of priority of British Patent Application No. GB2019458.5 filed Dec. 10, 2020, both of which are incorporated by reference in their entireties. The International Application was published on Jun. 16, 2022, as International Publication No. WO/2022/123252.

The present invention relates to an apparatus for breaking down material to a predetermined size. The present invention also pertains to a method of breaking down materials, preferably using such an apparatus. Furthermore, the invention relates to a system which includes an excavating machine and an apparatus for breaking down material, mountable onto said excavating machine. In the mining, quarrying, recycling, and demolition industries, large and/or irregularly sized materials can be broken down or reduced in size using an apparatus to provide an end product of predetermined size. One such apparatus is a cone crusher. A cone crusher typically has a housing, also referred to as a drum or hopper; and a cone-shaped element that has a rotatable mantle. A gap is provided between the rotatable mantle and the housing. Material to be broken down enters the housing before being crushed in the gap by the action of the mantle against the housing. Once broken down to the predetermined size, the end product exits the housing via the gap.

Cone crushers are characterised in that they have gyratory rotation in-use. In other words, the mantle undergoes eccentric rotation or has epicyclic loading. As a result, the gap has a variable radial width along the circumference of the mantle.

Although new material is constantly being crushed, as only a small fraction of the mantle is crushing material at any one time, resulting in low crushing efficiency. Due to the variable radius of the gap, material exiting the apparatus may have a non-uniform size.

Existing cone crushers or other such devices for breaking down materials are also provided as large-scale dedicated devices, increasing spatial requirements to store the machines on site. Ensuring the machines are available and onsite when required increases the complexity of the logistics. Where material to be broken down is loaded into the cone crusher manually, the through-put of the cone crusher is at least in part limited by the labour force available whilst the risk of injury is increased.

It is also currently not possible to easily insert or remove individual parts of an apparatus, such as the drive unit.

The present invention seeks to provide a solution to these problems.

According to a first aspect of the present invention, there is provided an articulable-arm-mountable pulverisation apparatus for reducing material size, the apparatus comprising: a material-receiving housing having a material-processing chamber, a discharge outlet portion, and a drive-unit compartment; an articulable-arm mounting element for releasably attaching the apparatus to an articulable arm of an excavating machine; a rotatable element in the material-processing chamber and having a side surface which, together with an interior surface of the material-processing chamber, forms a tapering pulverising material flow-path towards the discharge outlet portion; and a unitary drive unit in the drive-unit compartment, the drive-unit compartment having an openable access cover, whereby the unitary drive unit can be slidably removed in an axial direction as one-piece from the drive-unit compartment for utilisation of the unitary drive unit in a different apparatus. In other words, the unitary drive unit can be removed so that it can be used in a different apparatus.

The term “pulverisation” used herein and throughout is intended to mean the breaking down of material to provide an end product of predetermined or generally predetermined size, and/or within a range of predetermined sizes. The predetermined size may include fragments, rubble, granules, stones, small rocks, gravel, or other such similar particulate matter, and as such, is not limited to powder or dust particles.

The apparatus may be modular. Individual parts of the apparatus are replaceable or more easily replaceable without requiring disassembly or substantial disassembly of the whole apparatus. This provides greater ease of use and versatility as different drive units and/or rotatable elements having different characteristics may be selected. Furthermore, replacement of any worn or broken individual parts may also be cheaper and/or faster than replacing the whole apparatus.

Material to be reduced in size may include, by way of example only, building and/or demolition materials, such as bricks; stones; rocks; mineral matter; aggregate matter; or any other material which is to be broken down.

The drive-unit compartment may extend at least in part into the material-processing chamber. Furthermore, the drive-unit compartment may extend at least in part into or through the discharge outlet portion. Compactness of the apparatus is increased.

Additionally, the drive-unit compartment may be closable or substantially closable by the rotatable element. The rotatable element may be versatile or multi-functional. The rotatable element selectably closes the drive-unit compartment and breaks down material. Separate parts performing each function are not required, simplifying manufacture, together with reducing the weight and cost of the apparatus.

Optionally, the drive-unit compartment may extend axially outside of the material-processing chamber and/or outside of the discharge outlet portion. This may facilitate the ease of locating and/or accessing the drive-unit compartment. The ease of removal and/or insertion of the drive-unit or parts thereof may be increased.

Preferably, the material-processing chamber may have a chamber axis and the rotatable element may have a rotatable-element axis of rotation which may be or be substantially coaxial with the chamber axis. The rotatable element may have symmetrical rotation, rather than eccentric or gyratory rotation. The efficiency of the apparatus may be increased. Furthermore, if a gap between the rotatable element and the interior surface of the chamber is or is substantially uniform in width along the periphery of the rotatable element, the end product may be more uniform in size.

Preferably, the rotatable element may be tapered. The taper enables a gradual wearing down of material inserted into the material-processing chamber, which may further increase uniformity in the size of the end product. Tapering of the rotatable element also increases the volume to receive material in the material-processing chamber. Greater material aggregates and/or a greater volume of material may be processed.

Optionally, the rotatable element may be a frustum. The risk of the tip of a conical or pyramidal rotatable element being damaged or broken may be reduced. The rotatable element may also be more economical to manufacture as requiring less raw materials. The rotatable element may also be lighter as a result. The power and/or energisation requirements to lift and/or rotate the rotatable element may therefore advantageously be reduced.

Beneficially, the rotatable element may be or be substantially a polygon in a transverse cross-section. Optionally, the polygon may be a decagon. A rotatable element polygonal in a cross-section transverse to the chamber axis has planar or substantially planar surfaces against which material to be broken down may abut. In turn, planar surfaces may better engage the material via a greater surface area, at least compared to a curved surface.

Alternatively, the rotatable element may be or be substantially curved, and more preferably circular in a cross-section, preferably a cross-section transverse to the chamber axis. To this end, the rotatable element may therefore be cylindrical, conical, or frustoconical.

Furthermore, the material-processing chamber may be or be substantially cylindrical. Alternatively, the material-processing chamber may be or be substantially polygonal in a cross-section, preferably transverse to the chamber axis. By being cylindrical rather than inwardly tapering in a chamber-outlet to chamber-inlet direction, the material-processing chamber may temporarily hold and/or process a greater volume of materials in one batch. Additionally or alternatively, material fragments of greater volume may be inserted through the chamber-inlet. Preferably, the material-processing chamber may further comprise a grip-enhancing element. Additionally or alternatively, the rotatable element may or may also comprise a further grip-enhancing element. Furthermore, the or each grip-enhancing element and/or further grip-enhancing element may comprise at least one rib. Rotation of the rotatable element in conjunction with at least one rib associated with the material-processing chamber may enhance the pulverising efficiency of the apparatus.

Additionally, the articulable-arm-mountable pulverisation apparatus may further comprise at least one mixing-enhancing element, extending radially from the or an interior surface of the material-processing chamber. Optionally, the at least one mixing-enhancing element may be or be substantially a trapezium in axial cross-section. The or each mixing-enhancing element may be multi-functional or versatile by having any or any combination of the following functions: increasing the breaking down of the materials by increasing shearing forces acting on the material, acting as a strengthening bracket, partitioning broken down material, and supporting and/or bracing against the rotatable element. The term “trapezium” used herein and throughout is intended to mean a four-sided shape having a pair of parallel opposite sides.

Furthermore, the articulable-arm-mountable pulverisation apparatus may further comprise a further said rotatable element, interchangeable with the first said rotatable element. Beneficially, the further said rotatable element may have a different dimension to the first said rotatable element for selecting the size of material exiting the pulverisation apparatus. The rotatable elements may be easily interchanged, for instance, if one is damaged or if a different-sized end product is required.

According to a second aspect of the present invention, there is provided an articulable-arm-mountable pulverisation apparatus for reducing material size, the apparatus comprising: a material-receiving housing having a material-processing chamber, a discharge outlet portion, and a drive-unit compartment for receiving therein a unitary drive unit which is slidably removable, optionally as a one-piece; an articulable-arm mounting element for releasably attaching the apparatus to an articulable arm of an excavating machine; and a rotatable element in the material-processing chamber and having a side surface which, together with an interior surface of the material-processing chamber, forms a tapering pulverising material flow-path towards the discharge outlet portion. The size of the broken-down material may be more homogenous. The throughput of the apparatus may be greater, which may result in a higher efficiency.

Beneficially, the articulable-arm-mountable pulverisation apparatus, preferably in accordance with the first and/or second aspects of the invention, may further comprise a scoop element. The scoop element may dispense with manual loading of material into the housing and/or increase the volume of material of a batch.

According to a third aspect of the present invention, there is provided a system comprising an excavating machine and a pulverisation apparatus, preferably in accordance with the first and/or second aspects of the invention. An existing excavating machine, such as an excavator, can be fitted with a pulverisation apparatus or module. This may be cheaper and/or logistically easier than a dedicated, single-function apparatus for breaking down material.

Optionally, the system may comprise at least two drive units, each drive unit being receivable within the drive-unit compartment of the pulverisation apparatus and being interchangeable with the other said drive unit. A damaged drive unit may easily be replaced. If a specific task requires a different drive unit, such as having a more powerful motor by way of example only, the appropriate drive unit may be inserted into the drive-unit compartment.

According to a fourth aspect of the present invention, there is provided a system comprising an excavating machine and a plurality of attachable apparatuses, at least one of which is a pulverisation apparatus, preferably in accordance with the first aspect of the invention, wherein the drive unit is usable with another of the plurality of attachable apparatuses. A single, common drive unit may be usable with a plurality of, optionally different, apparatuses. A common interface enables a plurality of, preferably different, apparatuses to be attachable to the same excavating machine.

According to a fifth aspect of the present invention, there is provided a method of pulverising material, the method comprising the steps of: a] providing an excavating machine and a pulverisation apparatus, preferably in accordance with the first and/or second aspects of the invention; b] mounting the pulverisation apparatus onto an articulable arm of the excavating machine; c] rotating the rotatable element relative to the material-receiving housing and inserting material to be pulverised into the material-receiving housing, such that the material is broken down, preferably by shearing caused by the rotation of the rotatable element relative to the material-receiving housing and/or vice-versa. As the rotatable element breaks down material across a greater area than a corresponding gyratory cone crusher, the energetic requirements of the pulverisation apparatus may be lower. The end product may therefore be more homogenous in size.

Referring firstly to, there is shown an apparatus, indicated generally atfor breaking down or reducing the size of the material. In other words, the apparatusis adapted to reduce material size. In, the apparatusis shown in an assembled condition.shows the same apparatusin an exploded view.

The apparatusmay comprise metal, plastics, any other suitable material, or any combination of the above. More preferably, the apparatusor parts thereof is rigid cast or moulded metal, but other forms of material may be considered. Preferably, the apparatusor parts thereof may be easily connectable and disconnectable, although this feature may be omitted. This may increase the ease of replacement. The apparatusmay therefore be modularly-assembleable. Preferably, the apparatusis connectable to or mountable onto an excavating machine, preferably an articulable arm thereof, although this feature may be omitted. The apparatusmay be referred to as an articulable-arm-mountable pulverisation apparatus, module or attachment, a pulverisation apparatus, or pulverising apparatus, fragmentation or fragmentalisation apparatus. The apparatushas a housing, a rotatable portion, at least one drive unit, an articulable-arm mounting element, and a scoop, although any of these features may be omitted.

The housingin-use receives and/or holds fora period of time material to be broken down. The housingis therefore at least partly hollow to receive materials therein. The housingmay alternatively be referred to as a material-receiving housing, a container, a drum, or a hopper. The housingpreferably has a material-processing chamber, a discharge outlet portion, and a drive-unit compartment, although any of the last two features may be omitted.

The housing, and more preferably, the material-processing chamberthereof, acts together with the rotatable portionto break down material inserted into the housingin use. The material-processing chambermay also be referred to as a main body or primary compartment. More preferably, at least one of: the material-processing chamberand the rotatable portionis rotatable relative to the other in use preferably only the latter in the present embodiment. The cooperation of the material-processing chamberand the rotatable portiontogether breaks up the material in use.

Although in the present embodiment, the rotatable portionis rotatable, in an alternative embodiment, the rotatable portion may not be rotatable. For instance, the housing or part thereof may be rotatable.

As shown in, the material-processing chamberhas at least one chamber-wall, a chamber volume, a chamber-inlet, and a chamber-outlet. The material-processing chambermay further comprise a chamber axisand a grip-enhancing elementas shown in, but either or both features may be omitted. If one chamber-wallis provided, the chamber-wallhas an interior surface, and an outer surface. If a plurality of chamber-wallsis provided, each chamber-wallmay have an interior-surface portion and/or an outer-surface portion. The plurality of interior-surface portions collectively forms an interior surface. Similarly, the plurality of outer-surface portions collectively forms an outer surface

The apparatusmay be considered to have a front-to-back direction or orientation, wherein the material to be pulverised is inserted into the chamber-inlet, corresponding to the front, and wherein the pulverised material exits the apparatusvia an exit, corresponding to the back. For clarity, this terminology may be maintained even when the apparatusmay be oriented differently, for example when the chamber-inletfaces away from a ground surface, by way of example only.

The interior surfacemay also be referred to as an inner surface, a cone-facing surface, rotatable-portion-facing surface, or a pulverising chamber-surface. The interior surfaceand/or outer surfaceare preferably curved in transverse cross-section, but non-curved or part curved may be options. Preferably, the material-processing chamber, or at least one of: the interior surfaceand the outer surfaceis or is substantially circular in a cross-section transverse to the chamber axisbut non-circular may be an option. Most preferably, the material-processing chamberis or is substantially cylindrical but non-cylindrical may be an option. In other words, the material-processing chamberdoes preferably not taper in any direction.

The chamber-outletconnects the material-processing chamberto the discharge outlet portion. The chamber-outlethas an aperture or opening, preferably only one, but a plurality of apertures may be envisioned. The chamber-outletin-use provides an access or conduit for broken up material to exit the material-processing chamber

The chamber axis, indicated as a dashed line in, is preferably centrally positioned in the chamber volumeand/or housing, but non centrally positioned may be an option.

The discharge outlet portionis the portion of the housingwhich in-use provides a conduit or access for the pulverised material to exit the apparatus. The discharge outlet portionhas at least an end wall or platewhich may be planar, non-planar, or part planar, and an outlet. The discharge outlet portionalso has one or more side wallsand a through borethrough which at least part of the drive-unit compartmentand/or the drive unitmay extend, but any of these features may be omitted. The one or more side wallsmay optionally be connectable, connected, or integrally formed with the at least one chamber-wall. The outletcomprises at least one, and here a plurality of apertures. The or each aperturemay be formed by a through-bore or a recess in at least one of: the end wall, and the, each or a said side wall. One or more reinforcement strutsmay optionally be provided.

The drive-unit compartmentmay in-use receive and/or protect at least part of the drive unit. Preferably, the drive unitis removable from and/or insertable into the drive-unit compartment, optionally as one piece, but non-removable may be an option. Preferably, the drive unitis slidably removable and/or insertable. Preferably, the drive-unit compartmentmay only receive one drive unitat a time, but it could be envisioned that the drive-unit compartment may receive a plurality of drive units simultaneously.

As shown, the drive-unit compartmentextends outside of or from the material-processing chamberand/or the discharge outlet portion, but any of these features may be, once again, omitted.

The drive-unit compartmentpreferably also extends at least in part into or through the discharge outlet portionas shown, but this feature is optional. More preferably, a wall or walls of the drive-unit compartmentmay be connected or connectable with the end wall, preferably at or adjacent to the through boreof the discharge outlet portion. The wall or walls of the drive-unit compartmentmay optionally extend beyond the through boreand at least partly into the material-processing chamber. The drive-unit compartmentextends preferably axially or substantially axially, or parallel to the chamber axisfrom the discharge outlet portionand/or material-processing chamber, but these features may be omitted. The drive-unit compartmentis preferably tubular or cylindrical but any non-tubular or non-cylindrical shape is an option.

The drive-unit compartmentmay have at least one access opening. The access opening may be permanently open or selectably openable. If selectably openable, the access opening may be at least partly closable or substantially closable, or sealable. Preferably an access opening is provided at or adjacent to the back end of the housingand/or drive-unit compartment. Additionally or alternatively, a further access opening may be provided at, adjacent to, or facing the front end of the housingand/or drive-unit compartment. The drive-unit compartment, and more preferably, the access opening and/or further access opening may even be closable by the rotatable portionor part thereof. The rotatable portionmay even form or at least partly complete, form or define at least part of the drive-unit compartment. The ability to selectably open and close an access opening to the drive-unit compartmentby the rotatable portionor part thereof may enable the drive unitto be accessible and/or at least parts thereof to be easily inserted and/or removed from the front of the housing.

The drive-unit compartmentmay optionally have at least one abutment lip or edgeagainst which the drive unitmay abut and/or to which the drive unitmay be connectable. The drive-unit compartmentmay also optionally have an openable access cover, but this feature may be omitted.

The openable access coverhas a protective and/or sealing function. More preferably, the openable access covermay in-use prevent or inhibit access to an internal volume of the drive-unit compartmentand/or to a drive unitreceived within the drive-unit compartment. The openable access covermay be connectable or connected to the drive-unit compartment. The openable access covermay be receivable inside the material-processing chamberand/or a discharge outlet portionbut preferably is positionable or engageable with the back or outer end portion of the drive-unit compartment. More preferably, the openable access coveris engageable with the access opening at or adjacent to the back end.

As previously mentioned, the material-processing chamberpreferably also has a grip-enhancing element or grip-enhancer, but this feature may be omitted. The grip-enhancing elementis preferably associated with or disposed on the interior surface. Preferably the grip-enhancing elementin-use may reduce, inhibit, oppose, or prevent at least lateral translation of material relative to the interior surface. Furthermore, the grip-enhancing elementdoes not reduce, inhibit, oppose, or prevent translation axially or longitudinally along the interior surfacebut this feature may alternatively be provided.

In the preferred embodiment, the grip-enhancing elementcomprises at least one, and preferably as shown, a plurality of ribs, referred to as chamber-ribsfor clarity.

Although preferably chamber-ribs are provided, the grip-enhancing element may additionally or alternatively comprise a protrusion; a projection; a groove; a slit; a coating, layer, or portion having increased friction; or any other suitable feature which may in use enhance shearing effectiveness. Each chamber-ribis preferably linear but non-linear may be an option, such as curved, part-curved, saw-toothed, sinusoidal, or any other suitable shape, pattern, or configuration. The, each, or at least one chamber-ribmay be connectable or connected but preferably is integrally formed with the interior surface. The at least one chamber-ribmay extend at least partly in an axial or longitudinal direction. Thus, the at least one chamber-ribmay have a longitudinal extent. Preferably, the, each or at least one said chamber-ribonly extends in the axial or longitudinal direction. However, it could easily be envisioned, that the, each or at least one chamber-rib may additionally or alternatively extend at least partly in or solely in a lateral or transverse direction. In other words, a said chamber-rib may extend circumferentially or perimetrically along the interior surface

At least one chamber-ribmay extend from a position axially spaced-apart from the chamber-inlet. Additionally or alternatively, at least one chamber-ribmay extend to a position axially spaced-apart from the outletand/or chamber-outlet. In other words, at least one chamber-ribmay have a longitudinal extent which may be less than a longitudinal extent of the material-processing chamberand/or the material-processing chamberand the discharge outlet portion. In the preferred embodiment, at least one, and preferably as shown, each chamber-ribextends along a minor portion of the longitudinal extent of the housing, but a major portion may be envisioned. A plurality of chamber-ribsmay be axially and/or laterally staggered, regularly and/or irregularly, along and/or around the interior surface, but non-staggered may be an option. As shown, the chamber-ribsare preferably alternatively axially staggered.

Furthermore, the apparatusmay optionally comprise at least one, and here a plurality of mixing-enhancing elements. The or each mixing-enhancing elementmay be referred to as a mixing-enhancing part, a partition, a partitioning element, a fin, a fin element, a structural support element, a spacer, or a centering element. Each mixing-enhancing elementis connectable, connected, or integrally formed with the end wall or plate, and at least one of: the or a said side wallof the discharge outlet portionand the or a said chamber-wall. Two or more mixing-enhancing elementsare preferably spaced apart laterally or perimetrically around the interior surface